OK, here's how I use bullet cartridge's as scale rivets.
Materials needed:
4 cartridge casings. I used .270 or .243, but it will depend on what drills you have available.
A 12mm brad point drill bit or a 12mm Forstner bit would be ideal. You want the hole for the cartridge to be flat on the bottom if possible.
2 rivets, 3/16" head diameter, 1/16" thick, 7/16" long each. (these are close to the diameter of the primer. The hole in the tang should be 1/8".
A short piece of 1/8"x.014" brass tube (this is the material for a "washer" or spacer which will make the rivet flush with the surface of the casing. Otherwise the rivet would be recessed, which is ok if you like it.)
Process:
Drill your tang holes for about 3 hidden pins, plus 1/8" holes for your rivets. I used two, but you might like three cartridge holes.
Put the cartridge in a vise, punch out the primer.
Cut off the casing near the thick part of the cartridge. The idea is to make each cartridge base as close to the same thickness as possible. If you are using a brad point drill, it's ok to leave a little casing extending beyond the base, as your brad point will leave a little mound at the bottom of the hole in the scale.
Drill out the primer hole with a 1/8" drill so the rivet will fit thru. Dry fit.
Attach one scale, drill from tang side through the scale. Attach the other scale, drill thru from the previously drilled side.
Shape the handle to its final thickness, leaving a flat area for the cartridge.
Using the 1/8" hole as the center, drill the hole for the cartridge casing. Be careful to drill just deep enough so that the face of the cartridge is just flush with the scale. (Note, if you use a belt sander it can take off all the lettering and numbers in a jiffy if you are not careful. Suggest hand sanding only from here on out.)
Seat your cartridges with epoxy or CA. Keep the hole thru the tang and scale open while the adhesive cures.
When it is cured, take the 1/8th brass tube, cut off a piece and grind it to be 1/16" long. This piece will slip over both ends of the rivets so that the rivet will be flush with the surface of the cartridge, looking like a real primer. Dry fit.
Set the rivet using a punch. Be careful to drive it straight.
(you can also center punch the rivet head to look like it has been hit by the firing pin.) Seal with CA.
I hope someone out there can come up with a better/easier way to do this. I'd love to hear your ideas.
Note 1: If you want to use rimmed pistol cartridges, you can, but it will involve finishing the handle scales to the thickness you want, then counter-sink the depth of the rim, then using the same pilot hole, drill the cartridge hole.
Note 2: I would recommend trying this on a piece of wood about the thickness of your handles before drilling your finished scales. I screwed up several...
